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HAZARDOUS AREA TECHNICAL GUIDE

The Redapt Hazardous Area Technical Guide provides an
overview for the design and use of equipment used within
potentially explosive atmospheres created by gases, vapours
and ignitable dusts or fibres.
Typically this includes such installations as oil/gas rigs, processing
refineries, chemical production facilities, flammable liquids storage
facilities, fuel transportation, petrol stations, paint production, paper
production etc, however this list is not exhaustive and many new areas
may be re-classified as hazardous.

FUEL

OXYGEN

A hazardous area is defined as an area in which the atmosphere

contains, or may contain in sufficient quantities, flammable or
explosive gases, dusts or vapours. In such an atmosphere a
fire or explosion is possible when three basic conditions are
met. This is often referred to as the hazardous area or
combustion triangle.

In order to protect installations from a potential

explosion a method of analysing and classifying a
potentially hazardous area is required. The purpose
of this is to ensure the correct selection and
IGNITION
installation of equipment to ultimately prevent
SOURCE
an explosion and to ensure safety of life. The
methods used to classify an installation can
vary depending upon which part of the world
it is located, but generally there are two main
types of classification. In countries that have
adopted the IEC (International Electrotechnical Commission) philosophy
this is referred to as Zoning whilst in North American installations are
classified by Classes, Divisions and Groups to ascertain the level of
safety required.

Redapt Engineering Company Limited

Units 46 & 47
Darlaston Central Trading Estate
Salisbury Street, Darlaston
West Midlands. WS10 8XB
United Kingdom
Telephone No.: 44 (0) 121 526 7058
Fax No.: 44 (0) 121 526 5076
Email: redapt@redapt.co.uk

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SECTION 1
Classification -IEC and ATEX Standards
A Hazardous Area is defined by three main criteria, these being:
The type of hazard (groups)
The auto-ignition temperature of the hazardous material (temperature or
T rating)
The likelihood of the hazard being present in flammable concentrations
(zones)

The Type of Hazard

The type of hazard will be in the form of either a gas or vapour or a dust
or fibre.
The classification of these hazardous is primarily divided into two
groups depending on whether it is in a mining or above surface
industry. These are defined below:
Group I -electrical equipment for use in mines and underground
installations susceptible to firedamp Group II and Group III -electrical
equipment for use in surface installations
Groups II & III are further sub-divided depending upon the hazard.
Group II gases are grouped together based upon the amount of energy
required to ignite the most explosive mixture of the gas with air. Group
III dusts are subdivided according to the nature of the explosive
atmosphere for which it is intended.

Mining

Surface Industry

Group I

Group II

Electrical equipment for mines Electrical equipment for places with

susceptible to firedamp
an explosive gas atmosphere

Group III
Electrical equipment for places with an
explosive dust atmosphere

Sub-Division

Ignition Energy

Sub-Division Explosive Atmosphere

IIA

260 Microjoules

IIIA

Combustible flyings

IIB

95 Microjoules

IIIB

Non-conductive dust

IIC

18 Microjoules

IIIC

Conductive dust

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Auto Ignition Temperature or T Rating

The hazard level of the gases increases from gas group IIA to IIC with
group IIC being the most severe. Substances in this group can be
ignited very easily with Hydrogen being the most at risk to ignition. The
temperature class is based on the auto-ignition temperature of the gas,
details of which are given below.

Apparatus Groups and Temperature Classes for Common

Flammable Gases and Vapours Group II
Gas
Group

Temperature Class
T1

Methane

IIA

T2

T3

T4

Acetone

Ethanol

Diesel fuel

Acetaldehyde

Methane

Cyclohexane

Aircraft fuel

Ethane

Propanol 2

Fuel oil

Benzene

N-Butyl alcohol

N-Hexane

Methanol

N-butane

Heptane

Toluene

T5

T6

Kerosene

Propane
Acetic Acid
Ammonia
IIB

Coal Gas

Ethylene

Ethylene glycol

Ethylene oxide

Hydrogen Sulphide

Propanol 1

Tetrahydrofuran

Ethyl Methyl Ether

Methyl Ethyl
Ketone
IIC

Hydrogen

Acetylene

Temperature Class Rating for Group II Electrical Apparatus

Group II Temperature Class
T Code

Maximum Surface Temperature

Ignition temperature

T1

450C

> 450C

T2

300C

> 300C 450C

T3

200C

> 200C 300C

T4

130C

> 130C 200C

T5

100C

> 100C 135C

T6

85C

> 85C 100C

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If a hazardous is present the equipment used within the installation

must be given an appropriate T classification in order to maintain the
integrity. If that hazardous is, say, hydrogen, then all equipment used
must meet the T6 rating. This means that all equipment used must
not have a surface temperature of greater than 85C. Any equipment
used that can generate a hotter surface temperature of greater than
85C must not be used as this will then increase the likelihood of an
explosion by igniting the hydrogen in the atmosphere.

Apparatus Groups and Temperature Classes for Common

Flammable Dusts and Fibres Group III
When considering installations that are at risk of a potential explosion
due to dust ignition, the equipment used is classified in much the same
way as with gases. No equipment should be installed where the surface
temperature of the equipment is greater than the ignition temperature
of the given hazard. Below are some common dust hazardous and their
minimum ignition temperature.
Ignition Temperatures for Common Flammable Dusts and Fibers
Material

Ignition Temperature
Cloud

Layer

Coal Dust

380C

225C

Polythene

420C

(melts)

Methyl Cellulose

420C

320C

Starch

460C

435C

Flour

490C

340C

Sugar

490C

460C

Grain Dust

510C

300C

Phenolic Resin

530C

> 450C

Aluminium

590C

> 450C

PVC

700C

> 450C

Soot

810C

570C

The Likelihood of the Hazard

The likelihood of the hazard being present in a concentration high
enough to cause an ignition will vary from location to location. For
most installations this risk is dependant upon how long the hazard
(gas, vapour, dust or fibre) is present. In order to classify this danger an
installation is divided into areas of risk depending upon the amount of
time the hazardous is present. These areas are referred to as Zones.

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For gases and vapours and dusts and fibres there are three zones:
Gas

Dust

Hazardous Area Characteristics

Zone
0

Zone
20

A hazardous atmosphere is highly likely to be present and may be present for long
periods of time (>1000 hours per year) or even continuously

Zone
1

Zone
21

A hazardous atmosphere is possible but unlikely to be present for long periods of time
(>10 <1000 hours per year

Zone
2

Zone
22

A hazardous atmosphere is not likely to be present in normal operation or infrequently

and for short periods of time (<10 hours per year)

Protection Concepts
There are varying types of equipment that can be used within these
zones to ensure that the potential for an explosion is removed or
greatly reduced. This equipment must be designed and manufactured
in accordance with particular construction parameters known as
protection concepts. Essentially these concepts fall under four
main methods. These methods are detailed below along with a brief
description of some of the concepts:
Type of Protection
Method

Equipment
Code

Description

International
Standard

Suitable for
Zones

Intended to prevent a
potential ignition arising

Ex e

Increased safety

IEC 60079-7

1, 2

Ex nA

Type -n protection

IEC 60079-15

Ex ia

Intrinsic safety ia

IEC 60079-11

0, 1, 2

Ex ib

Intrinsic safety ib

IEC 60079-11

1,2

Ex ic

Intrinsic Safety ic

IEC 60079-11

Ex nL

Type -n protection

IEC 60079-15

Ex p

Purge/pressurized protection

IEC 60079-2

1, 2

Ex px

Purge/pressurized protection px

IEC 60079-2

1, 2

Ex py

Purge/pressurized protection py

IEC 60079-2

1, 2

Ex pz

Purge/pressurized protection pz

IEC 60079-2

Ex m

Encapsulation

IEC 60079-18

1, 2

Ex ma

Encapsulation

IEC 60079-18

0, 1, 2

Ex mb

Encapsulation

IEC 60079-18

1, 2

Ex o

Oil immersion

IEC 60079-18

1, 2

Ex nR

Type -n protection

IEC 60079-15

Ex d

Flameproof protection

IEC 60079-1

1, 2

Intended to limit the

ignition energy of the
equipment

Intended to prevent the

explosive atmosphere
contacting the ignition
source

Intended to prevent an
ignition from escaping
outside the equipment

Ex q

Sand / powder (quartz) filling

IEC 60079-5

1, 2

Ex nC

Type -n protection

IEC 60079-15

Special

Ex s

Special protection

See IEC 60079-0

0, 1, 2

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Ex i Intrinsic Safety
A protection concept in which the electrical energy within the
equipment is restricted to a level which is below that what may cause
an ignition or to limit the heating of the surface of the equipment. There
are two main sub types to Ex i protection, these being ia and ib.
Type ia protection allows for the occurrence of two faults during
operation
Type ib protection allows for the occurrence of one fault during
operation.
Ex d Flameproof
The equipment that may cause an explosion is contained within an
enclosure which can withstand the force of an explosion and prevent
transmission to the outside hazardous atmosphere. This method of
protection also prevents the hazardous atmosphere from entering the
enclosure and coming into contact with equipment.
Ex m Encapsulation
A protection concept where by equipment that could potentially
cause an ignition is encapsulated within a compound or resin so as
to prevent contact with the explosive atmosphere. The concept also
limits the surface temperature of the equipment under normal operating
conditions.
Ex e Increased Safety
Precautions are applied to the installation to ensure increased security
against the possibility of excessive temperatures and sparks from
electrical equipment. Equipment that normally causes sparks is
excluded from use within this method of protection.
Ex p Pressurised
One process ensures that the pressure inside an enclosure is sufficient
to prevent the entrance of a flammable gas, vapour, dust, or fibre and
prevent a possible ignition. Another process maintains a constant flow
of air (or an inert gas) to dilute to take away any potentially explosive
atmosphere.
Ex o Oil Immersion
All equipment that has the potential to arc and potentially cause an
ignition is immersed in a protective liquid or oil. The oil provides an
insulating method to prevent ignition.
Ex q Powder Filling
All equipment that has the potential to arc is contained within an
enclosure filled with quartz or glass powder particles. The powder
filling prevents the possibility of an ignition.

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Ex n Non-Sparking
A type of protection where precautions are taken so that electrical
equipment that has the potential to arc is not capable of igniting a
surrounding explosive atmosphere. This can be further categorised
as follows: Ex nA -Where components used in construction are nonsparking Ex nC -Where components used in construction are nonincendive Ex nR Where components used are tightly enclosed to
restrict the breathing and prevent ignition Ex nL -Where components
used in construction do not contain enough energy to cause an ignition
Ex s Special
This method of protection, as its name indicates, has no specific
parameters or construction rules. In essence it is any method of
protection which can provide a pre-determined level of safety to ensure
that there is no potential for an ignition. As such it does not fall under
any specific protection method and may in fact be a combination of
more than one.
Ingress Protection
Another consideration in the protection of equipment in hazardous
areas is the safeguarding against the ingress of solid foreign objects
and water. This is known as the degree of ingress protection and is
commonly referred to as the IP Code. The relevant standard for the
degree of ingress protection is IEC 60529. An overview of the IP code
as defined in the standard is detailed below:
1st Numeral

Degree of Protection

2nd Numeral

Degree of Protection

No protection at all against solid objects

No protection at all against the

ingress of water

Protection against solid objects greater

than 50 mm in diameter

Protected against falling water

drops

Protection against solid objects greater

than 12.5 mm in diameter

Protected against falling water

drops at an angle of up to 15

Protection against solid objects greater

than 2.5 mm in diameter

Protected against sprayed water at

an angle of up to 60

Protection against solid objects greater

than 1.0 mm in diameter

Protected against the splashing of

water from any direction

Protected against the ingress of dust in

such an amount that it will not interfere
with the operation of the equipment

Protected against water jets from

any direction

Total protection against the ingress of

any dust

Protected against powerful water

jets from any direction

Protected against the ingress of

water when temporary immersed
between 0.15 m and 1 m

Protected against the ingress

of water when continuously
immersed to a specified depth

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Operational Temperatures
All equipment used within hazardous areas has an operational
temperature band or limit. This is often referred to as the Tamb
and defines the upper and lower ambient temperatures of which the
equipment is approved for use in. As defined in IEC 60079-0 the
standard limits are 20C to +40C. Where the operation temperatures
of the equipment fall between these parameters no additional marking
is required. However, if they are outside these parameters than the
specific temperatures need to be identified.
Marking of Hazardous Area Equipment
All equipment for use in hazardous areas should be marked as
prescribed in 60079-0. As a general rule this includes, where
appropriate, such information as:
- Company/Manufacturers name and address
- Hazardous area certificate number(s)
- Protection concept -Gas group(s)
- Temperature class
- Ambient temperature range
- Product identification
- Serial number and year of manufacture
- Electrical parameters
- CE marking and ATEX notified Body ID number
- ATEX coding -IP code

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SECTION 2
Classification North American Standards
In North American installations, hazardous areas are defined by
classes, divisions, and groups to classify the level of safety required for
equipment installed in these locations.
Classes define the type of hazard in terms of whether it is a gas or
vapour, a combustible or conductive dust or an ignitable fibre or flying.
Divisions define the probability of the presence of the hazard being
present during normal or abnormal conditions.
Groups classify the exact type and nature of the hazardous substance.
An overview of this classification system can be defined as follows:
Classes
Class

Definition

A location in which a flammable gas or vapour is or may

be present in sufficient quantity to cause an explosive
atmosphere

II

A location in which a conductive or combustible dust is or

may be present in sufficient quantity to cause a fire or an
explosive hazard.

III

A location in which easily ignitable fibres or flyings are

present in sufficient quantity to present a serious risk of fire

Classes
Class

Definition

The defined hazard is present during normal operational

conditions

The defined hazard is present only during abnormal

conditions such as equipment failure.

Groups
Class

Representative Hazard

Acetylene

Hydrogen
Ethylene

Propane

Metal Dust

Coal Dust

Grain Dust

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Marking of Hazardous Location Equipment

The marking of hazardous location equipment varies in accordance with
the relevant Electrical Code. As a general rule equipment should be
marked as follows:
- Company/Manufacturers name
- Class I, II and/or III
- Division 1 and/or 2
- Group A, B, C, D, E, F and/or G
- Approving NRTL (Nationally Recognized Testing Laboratory) logo
- Product identification
- Serial number
- Other relevant safety information
- Enclosure Type Rating
Basic UL / CSA / NEMA Enclosure Types
Type 3
An enclosure which is intended for outdoor use primarily to provide a
degree of protection against windblown dust, rain, sleet and damage
from external ice formation
Type 3R
An enclosure which is intended for outdoor use primarily to provide a
degree of protection against falling rain and damage from external ice
formation
Type 3S
An enclosure which is intended for outdoor use primarily to provide a
degree of protection against rain, sleet, windblown dust, and to provide
for operation of external mechanisms when ice laden
Type 4
An enclosure which is intended for indoor or outdoor use primarily
to provide a degree of protection against windblown rain and dust,
splashing water, hose directed water and damage from external ice
formation
Type 4X
An enclosure which is intended for indoor or outdoor use primarily to
provide a degree of protection against corrosion, windblown rain and
dust, splashing water, hose directed water and damage from external
ice formation
Type 6
An enclosure which is intended for indoor or outdoor use primarily
to provide a degree of protection against falling dirt, hose directed
water, the entry of water during occasional temporary submersion at a
specified depth and damage from external ice formation.

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Type 6P
An enclosure which is intended for indoor or outdoor use to primarily to
provide a degree of protection against falling dirt, hose directed water
and the entry of water during prolonged submersion at a specified
depth and damage from external ice formation.

This information has been compiled for guidance purposes only for equipment
intended for use in potentially explosive atmospheres. This guide was assembled
based on available technical knowledge at time of compilation. However
regulations and legislations are subject to updates and the information provided
within this guide may have been superseded. All equipment must be designed,
selected and installed in accordance with appropriate regulations and governing
legislation appropriate to its use.
Redapt Engineering Company Limited 2007

Redapt Engineering Company Limited

Units 46 & 47
Darlaston Central Trading Estate
Salisbury Street, Darlaston
West Midlands. WS10 8XB
United Kingdom
Telephone No.: 44 (0) 121 526 7058
Fax No.: 44 (0) 121 526 5076
Email: redapt@redapt.co.uk